Beka-mak Bmsy 360cgh User manual

MANUFACTURER / İMALATÇİ : BEKA-MAK MAKİNA SANAYİ VE TİC. A,Ş.

Address / Adres: İzmir Yolu 25.km Marmarabirlik yani 16370 Başköy-Bursa/Türkiye

Telefon : 02244490361 (4 hat )

Fax : 02244490360 Nilüfer / Bursa

Http : // www.bekamak.com.tr

E-mail : [email protected]

Warranty

-The firm guarantees the machine described hereby, designed in compliance with all regulations

in force, in particular safety and health regulations; the machine has undergone successful

testing.

-The warranty covers a period of 12 months. İt doesn’t cover electrical motors and tools.

-The purchaser is entitled ‘replacement of faulty parts’. Shipping and packing costs are at his

expense.

-The warranty doesn’t cover the parts damaged by falls or careless handling of the machine,

incorrect operation, non -compliance with the maintenance rules. Any tampering with the

machine, especially with the safety devices automatically expires the warranty and the

manufacturer will be freed from any responsibility.

-Any kind of alteration on the machine ends the warranty and the manufacturer becomes free

from every kind of responsibility.

-No claim for damages shall be accepted in case the machine lays idle for a long period of time.

-Machine is designed to be run indoors. İt is not recommended to run the machine outdoors.

The serial number on the machine is a ‘main reference for the warranty’, instructions manual, after

sale service and identify the machine in case of need.

Important

Upon the delivery of the machine, the consumer must make himself sure that all

the devices indicated in the paragraph of the safety manual are present and working

correctly. Furthermore, he must mount in conformity with the instructions indicated those

devices which are not mounted at the time of delivery to facilitate transport.

When ordering spare parts

İt is necessary to state:

ØMachine model

ØSerial number and year of production

Øİtem reference number

Without serial number no spare parts will be delivered

General İnformation

-The machines are manufactured in compliance with the accident prevention rules in

force.

-Strictly comply with the instructions contained in this manual to obtain the best

performance from the machine. Strict compliance with the rules co ntained herewith will

ensure optimum results and avoid any inconvenience caused by the non -compliance of

operation and maintenance instructions.

-Closely follow the instructions given below to avoid contacting the manufacturer for the

problems which can be easily solved..

-If after having strictly compliance with the given instructions, the purchaser still needs

the help of our technical assistance service, he must supply all the technical indications

necessary to determine the type of problem and/or the parts which are not functioning

correctly. This will enable our technical assistance service to intervene quickly and

efficiently on the machine.

Copies of the instruction manual may be requested upon indication of the machine serial

number.

General Safety Notes

All installation work including the electrical connection must only be carried out by qualified

personnel.

The machine must only be operated by a technically trained and experienced operative who is

also instructed in ‘safety at work ’ procedures.

Any adjustments, cleaning, repairs or changing of the saw blade must under no circumstances be

performed unless the machine is fully isolated from the electrical power supply. Ensure the

emergency stop button on the control binnacle is pressed and the power supplies at the mains are

disconnected.”

The band saw must be regularly inspected and maintained in good serviceable condition. Eye

protection, ear protection, gloves and protective clothing must be worn when any of the above

procedures are being carried out, as well as when cutting fluid is prepared, introduced or displaced

from the band saw machine (the relevant environmental regulations must be observed in case of

the use and disposal of cutting fluid etc.)

The band saw must be installed on ground. Obs erve the permissible floor load. Than the band

saw machine has been properly bolt to ground securely.

Allow sufficient working space around the band saw of at least 1 meter. İnstallations of stock roller

conveyors require additional space and possibly a lifting mechanism for heavy work pieces.

Always ensure that the working area around the band saw is well lit.

Safety İnstructions

ØBe sure that electrical connection is made carefully. To avoid unwanted situations like electrical shock, protect the mainsupply cable with a holster.

ØBefore running the machine, be sure that all of the protections are mounted properly and all the covers are closed.

ØAvoid from smoke and moisture.

ØPlease use the parts and equipments which are recommended. Usage of unsuitableparts and materials which are bigger than the capacity of the machine can cause unwanted situations.

ØCheck the machine and inform the defects everyday.

ØDon’t leave any material after chancing the band.

ØDo not hold the material while the machine is cutting. Always tighten the material by using essential parts.

ØPlease pay attention to choose the area of the machine which doesn’t include anything that creates difficulties to control the machine

ØPlease be sure that the teeth of the band are looking to correct direction.

·Don’t leave the band on the ground or any place that is dangerous for other people.

·Be careful when using the machine and keep the working area clean ( clean the saw dusts and oil traces )

·Pay attention to security instructions when using the machine.

·Don’t wear loose cloths when using the machine.

·Regardless use the protective gloves when using the machine.

·Don’t get close too much to the machine when running.

·Before carrying out any cleaning or maintenance procedure, disconnect the machine from main supply.

·İn some conditions, noise level can be about 85 db. Band choice and cutting speed is important factor for noise level.

·İllumination is an important factor for security.

·Ratio of coolant liquid is important for obtaining optimum lubrication.

·Never use the machine if you notice any fault of the machine or absence of any part of the machine.

-Control the emergency button at least once a week and be sure that it is working properly.

RELATED DIRECTIVES AND STANDARDS / ILGILI YÖNETMELIK VE STANDARTLAR

DIRECTIVES/DIREKTIFLER

MACHINERY DIRECTIVE-/MAKINE DIREKTIFI 2006/42/EC

LOW VOLTAGE DIRECTIVE/DÜŞÜK VOLTAJ DIREKTIFI 2006/95/EC

ELECTROMAGNETIC COMPATIBILITY DIRECTIVE/ELEKTRO MANYETIK UYUMLULUK DIREKTIFI- 2004/108/EC

STANDARDS/STANDARTLAR

EN ISO 13857:2008; SAFETY OF MACHINERY-SAFETY DISTANCES TO PREVENT DANGER ZONES BEING REACHED BY UPPER LOWER LIMBS/ KOL VE BACAKLARIN

ULAŞABILECEĞI BÖLGELERDE TEHLIKENIN ÖNLENMESI IÇIN GÜVENLIK MESAFELERI

EN ISO 4413:20106: HYDRAULIC FLU ID POWER – GENERAL RULES AND SAFETY REQU IREMENTS FOR SYSTEMS AND THE IR COMPONENTS / H IDROLIK AK IŞKAN GÜÇ –

SISTEMLER VE BILEŞENLERI IÇIN GÜVENLIK KURALLARI VE GENEL KURALLAR.

EN ISO 13849-1:2008/AC:2009; SAFETY OF MACH INERY - SAFETY-RELATED PARTS OF CONTROL SYSTEMS - PART 1: GENERAL PR INCIPLES FOR DES IGN / MAKINELERDE

GÜVENLIK- KUMANDA SISTEMLERININ GÜVENLIKLE ILGILI KISIMLARI- BÖLÜM 1: TASARIM IÇIN GENEL PRENSIPLER

EN 13898:2003+A1:2009/AC:2010: MACHINE TOOLS - SAFETY - SAWING MACH INES FOR COLD METAL /TAKIM TEZGÂHLARI – GÜVENLIK - METALLERI SOĞUK IŞLEME IÇIN

TESTERE TEZGAHLARI

EN ISO 12100:2010; SAFETY OF MACH INERY - GENERAL PR INCIPLES FOR DES IGN – RISK ASSESMENT AND R ISK REDUCT ION/ MAKINALARDA GÜVENL IK – TASARIM IÇIN

GENEL PRENSIPLER- RISK DEĞERLENDIRILMESI VE RISK AZALTILMASI.

EN 60204-1:2006/A1:2009; SAFETY OF MACH INERY - ELECTRICAL EQUIPMENT OF MACHINES - PART 1: GENERAL REQU IREMENTS / MAKINELERIN EMNIYETI – MAKINELERIN

ELEKTRIK DONANIMI – BÖLÜM 1: GENEL GEREKLER

Residual Risks

Do Not Touch Below Mentioned Moving Or Movable Parts Of The Machine While İt Runs.

Mechanical Dangers

Residual Risks

There might be the risk of hand/arm

incerceration between wheel cover and

control panel.

Necessary warnings are mentioned in the manual.

There are warning signs on the machine.

There might be the risk of hand incerceration

between piston hose and piston when the

head is down.

There is necessary and enough warnings in the manual.

There is warning sign at first part. There is warning sign on the

cover.

There might be the risk of hand/arm

incerceration between movable vice profile

and arm withdraw point.

There is necessary and enough warnings in the manual.

Warning sign has been put at related section.

There might be the risk of hand/arm

incerceration between arm and ear when

movable arm is at last point

There is necessary and enough warnings in the manual.

Warning sign has been put at related section.

There might be the risk of hand/arm

incerceration between hydraulic lifting piston

pipe and lug support profile, movable arm

piston pipe and piston upper connection

block during the up and down movement of

bow .

There is necessary and enough warnings in the manual.

Warning sign has been put at related section.

There might be snipping risk between

movable vice profile and movable arm

There is necessary and enough warnings in the manual.

Warning sign has been put at related section.

Warning

This chapter outlining the safety devices and norms was drawn up bearing in mind the normal use

of the machine as stated in the chapter on the operation of the machine and the adequate

preparation of the operators as regards the specific risks linked to the operation of the machine.

İf the machine isn’t used according to instruction given in the ‘purpose of the machine’ chapter in

this manual, the manufacturer isn’t responsible for any damage caused to people and things.

Furthermore, the manufacturer isn’t responsible for any damage to peop le and things and things

resulting from the non-compliance with the following warnings.

A) Adopt all the necessary precautions during loading, calibration, part replacement,

cleaning, and repair or maintenance operations to prevent someone else from turning

the machine on.

B) Do not temper with the safety devices and guards on the machine.

C) Do not remove any of the safety devices and guards on the machine.

Always make sure that safety devices and guards are remounted after their temporary removal for

technical reasons ordered by the boss

Connection To The Electrical System

Control panel is mounted on the electric panel. Machine is connected to the main

supply in the electrical panel. R, s and t shows the phases , n is neuter and pe is

grounding. Connection willbe from the 13(l1) klemens which is at right klemens group.

Check the voltage which is mentioned at the first page of the manuel before setting the

electrical connection of the machine.

İf the cable phase line is correct phase control led lightens in tha t way it is prevented to

motors move on wrong ways. Be sure that the out-put voltage at the power supply is 22 ~ 28

vdc.

The machine is protected against short circuit with interrupters and against high voltage with

thermal relays. Grounding and neutralizing have to be done to protect the machine .

Technical Data

TECNICAL DATA/TECHNISCE DATEN

BMSY 360CGH

Cutting Capacity

Schnittbereich

0°

Round/Rund

360

Flat/Flach

700 x 360

Square/Vierkant

360

Cutting Capacity

Schnittbereich

+30°

Round/Rund

360

Flat/Flach

590 x 360

Square/Vierkant

360

Cutting Capacity

Schnittbereich

+45°

Round/Rund

360

Flat/Flach

460 x 360

Square/Vierkant

360

Cutting Capacity

Schnittbereich

+60°

Round/Rund

305

Flat/Flach

305 x 360

Square/Vierkant

305

Main Drive Motor/Hauptmotor

Hydraulic Motor/Hydraulikmotor

0,55

Coolant Motor/Kühlmittelpumpe

0,12

Chip Conveyor Motor/Spaneförderer

0,25

Cutting Speeds/Schnittgeschwindigkeit

m/min

20 - 100

Band Dimensions/Sagebandabmessung

5000 x 34 x 1,1

Working Height/Arbeitshöhe

690

Weight/Gewicht

1550

Dimensions/Masse

Length/Länge

2850

Width/Breite

780

Height/Höhe

1800

Transportation And Carrying Of Machine

İmportant

Carry well-balanced with a strong rope which will be hooked to carrying rings

Statement of Noise

Conditions for measurement

Tested Machine: BMSY 360CGH–Blade size: 5000 x 34 x 1,1mm

Material in use: ø250 Solid Material

A Nominal sound pressure level in warehouse

Lpfa,1m=77db(a) Coefficient of uncertainty k:4 db (testing appropriate to en 11202)

A nominal sound power level

Power level lwa=69,7db(a) (mesaured value)

Coefficient of uncertainty k:4 db (testing appropriate to en iso 3476)

Values for noise are level of issue and it doesn’t state it’s on safe working level.Even there is a connection betweeen İssue and exposure levels, this can not be used safely to decide if advanced

precautions are needed. Factors that effect the real level of

exposure that effects work force aredepending on featuress of warehouse,(other sourses of noise, other works nearby, and quantity of machines) including exposuretime

Allowed level of exposure may change from country to another. Beside these, this information lets the operator to consider the dangers and risks.

Fixing

Area that machine will be fixed should be flat and bowless. Machine base should be placed

properly , linear and diagonal way . Get the machine to balance with 4pcs m12 screws that

are on the legs, you should fix it with ø13 steel pins.

Balancing The Machine

balancing the machine can be achieved by using the height adjustable screws. The

machine must be balanced on both directions.

Important : balance of the machine is one of the most important factors for the correct

working of the machine.

OPERATING INSTRUCTION

SPEED CONTROL POTMETER :CONTROLS THE

INVERTER TO ADJUST THE TURNING SPEED OF

BLADE

EMERGENCY STOP

BUTTON:PREVENTS ACCIDENTS AT

UNEXPECTING SITUATIONS.

START BUTTON : START THE CUTTING

STOP BUTTON :STOPS THE CUTTING

SIGNAL BUTTON : SHOW SIF THERE IS A PROBLEM

AT THE MACHINE.

COOLANT BUTTON :IT IS USED TOL

ET THE COOLANT LIQUID FLOW.

BOW UP BUTTON: MOVES THE BOW UP MANUALLY

AND STOPS CUTTING.

BOW DOWN BUTTON: MOVES DOWN

THE BOW MANUALLY.

START (READY) BUTTON:ENERGISES POWER CIRCUIT OF THE

MACHINE

VICE PRES BUTON: IT IS USED TO

PRESS THE MATHERIAL

BLADE TIGHTENING BUTTON: TIGHTEN THE

BLADE.

TOP CLAMPING

SELECTOR(OPTIONAL): THIS OPTION

IS FOR TIGHTENINK THE MATERIAL

VERTICALLY FOR BUNDLE CUTTING

DOWN FEED SPEED ADJUSTMENT: ADJUST SPEED

ACCORDING TO HARDNESS OF MATERIAL TO BE

CUT. WHEN BLADE BECOMES BLUNT CHOOSE A

LOWER SPEED TO HAVE A BETTER CUT.

ANGLE DISPLAY: DISPLAYS THE

POSITION OF BOW IN DEGREES

BETWEEN 0° AND +60°

The indicator of manometer must be in the green area (area ii). If the indicator is in one of the red area, this means that t he

tension of the blade is not in the acceptable level and it may cause unwanted results.

Area ı : this shows that the tension of the blade is less than it must be. Adjust the blade tension.

Area ıı : this shows that the tension of the blade is normal

area ııı : this shows that the tension of the blade is more than it must be. This may break

the blade. Reduce the tension.

HYDRAULIC VICE:40 BAR

HYDROMECANIC BLADE TENSION:300 BAR

HYDRAULIC BLADE TENSION:40 BAR

MAIN MOTOR:40 BAAR

Manual Cuttıng Operatıon

1-Add coolant to the tank

2-Check level of hydraulıc oıl(ıso 46)

3-Swıtch on maın swıtch

4-See energy on lıght on the control pannel

5-If there ıs no lıght change places of ınput phases

6-Press machıne ready button

7- Push bow up tıll ıt’s enough for materıal to be cut

8-Open the vıce by turnıng the related button.

9-Place the materıal. Adjust the lenght to be cut by lean shaft and close vıce jaws and fıx the materıal.

10-The saw wıll not start up unless the materıal ıs not clamped wıt approprıate pressure.

11-Start the saw by pressıng start button.

12-Determıne the approprıate saw cuttıng speed and turn on the coolant accordıng to your need.

13-Due to the materıal detectıon sensors on the machıne approached to the materıal fastly and then passes to the speed whıch ıs

adjusted by the valve.

14-When the machıne runs to the cuttıng speed , the coolant starts as well.

15-Cuttıng speed of the machıne should be adjusted accordıng to the materıal and chıp after cuttong process. For example; ıf thechıp

ıs burnt after the cuttıng that means the speed ıs too fast. That ıs not proper for the machıne and the blade.

16-After cuttong process the balde wıll rıse up and stop automatıcally.

17-The same should be done for the second cuttng.

18-Durıng the tıme there mıght pıle up chıp ınfront of the sensors , thıs mıght cause workıng problem to the machıne; to avıod that , the

wheel covers should be opened regularly and chıp should be cleaned.

Sensor Parts

(1)Blade broken pressure switch: this switch stops the main motor when the blade is broken and provides protection of

the operator and the machine from the damages that a broken blade can cause.

(2)Lower limit switch: this limit switch stop the main motor and starts the bow’s upwards movement.

(3)Laser: It is used as a marker for indicating first touching point of the blade to material.

(4)Maximum switch: this switch sets the top point that bandsaw reaches.

(5)Digital Angle Encoder:It is using for reading the angle of bow.

(8)Fotocell: this switch starts the main motor when the blade approaches to the material about 30 mm after the bow begins

going down when start button is pressed. And in manual use, this switch stops the movement before the bow crashes to

material when the bow is going down.

(9)Protection cover switches: this switch stops the machine if any cover is open.

1- Blade Broken Pressure Switch

2- Lower Limit Switch

3- Lazer

4- Maximum Switch

5- Dijital Encoder

6- Wheel Reductor

7- Wheel Motor

8- Protection Cover Switches

9- Fotocell

Instructıons For Maıntenance

Daıly Maıntenance

1-remove the chıps on wheel

2-clean the hydraulıc drawer

3- clean the chıps ın the boron oıl tank

pump aır to remove the dırth ın hoses

4. Remove the chıps at shaft and flat

5- manometer should be between ……………………. bar.

6. Clean the tensıonıng slıde flats.

Monthlty Maintenance

A-check the chıp brush.

B-fıll grease oıl from the hole on the tentıonıng shaft.

C- check the tıghtness of wheel bolts.

D.control the oıl level ın hydraulıc tank

E. Fıll grease oıl from the hole on the tensıonıng slıde

F-check the oıl level on reductor from dısplay ıncase of decreasıng add gear oıl (number

90)

Changing The Hydraulic Oil

Pouring Out The Hydraulic Oil

üLower down until it receives the cutting head.

üRemove hydraulic hose union at head lifting

üPut the removed hydraulic end of the hose into a container.

üEmpty the oil by pressing head lifting button at control panel.

After empting the oil, fix the hydraulic hose union to the same place.

Refilling the hydraulic oil

The hydraulic oil filling

üRemote the bolts of hydraulic drawer, then pull it out.

üOpen the store cover.

üPour 46 numbered iso hydraulic oil into tank. (8lt capacity.)

üClose the tank cover and move the drawer into the body

Fasten the screws to the body again with the help of hydraulic drawer.

Filling Of Coolant

Consisting of a mixture of liquid and water coolant liquid should be used for steel cutting. Coolant should not be used for cutting casting. Specific periods of time (at least once a month)

, coolant should be drained and clean chips. İf amount of coolant is not enough, add to the tank. (4 liters of tank capacity. Collant mixing ratio 1/10)

Setting New Blade

·First of all both guard flaps and the guards which are on the guide arms have to be open upwards.

·Loosen the blade by the hand level so far that the blade can be easily taken off around the pulleys

·The same way but vic averse, fit and tighten the new blade. There is also possibility to tighten the blade by torque meter.

·Always pay attention to the teeth of the blade’s direction is correct. İf not correct it.

Cutting Speeds

The machine has two pre-selected cutting speeds of 20 and 100 m/sec. Cutting speeds has to be selected according to the grade and dimensions of the m aterial. İf any vibration and/or

noise raises from the blade, change the speed.

·All the details about the cutting of various materials and dimensions are given below

CUTTING RECOMENDATIONS

NOTE:THE CUTTING SPEEDS GIVEN BELOW ARE GUIDELINES ONLY

MATERIAL

MATERIAL DESIGNATION

DIN

MATERIAL

CUTTING SPEED

COOLANT

SPECIAL

LG-SUPER

BI-

METAL

EMULSION

CUTTING OIL

YES

STRUCTUAL STEEL

ST 35 – ST 42

1.0308-

0077

40 - 55

60 - 80

1:10

ST 350 – ST 70

1.0052-

0070

30 - 45

50 - 70

1:20

HARDENING STEEL

C 10 - C 16

1.0301-

0401

45 - 65

60 - 90

1:10

14 NICR 14

1.5752

30 - 40

40 – 50

1:10

21 NICR MO 2

1.6523

30 - 45

45 - 55

1:10

16 MRCR 5

1,7131

30 - 45

50 - 65

1:10

NITRICTED STEEL

(HEAT TREATED)

34 CRAL 6

1,8504

------

20 - 35

1:20

34 CR AL NI 7

1,8550

------

20 - 35

1:20

FREE CUTTING STEEL

9 S 20

1,0711

45 - 65

70 - 120

1:10

HEAT TREATABLE STEEL

C 35 C 45

1,0501-

0503

35 - 55

55 - 75